ME(w/o STI)-93
Chain Cover
MECHANICAL
14.Chain Cover
A: REMOVAL
NOTE:
When replacing a single part, perform the work with the engine assembly installed to body.
1) When working on the vehicle
NOTE:
When working on the vehicle, perform the following steps also.
(1) Remove the intercooler. <Ref. to IN(w/o STI)-38, REMOVAL, Intercooler.>
(2) Remove the intake duct No. 2. <Ref. to IN(w/o STI)-25, INTAKE DUCT NO. 2, REMOVAL, Intake
Duct.>
(3) Remove the radiator. <Ref. to CO(w/o STI)-37, REMOVAL, Radiator.>
(4) Remove the front exhaust pipe. <Ref. to EX(w/o STI)-9, REMOVAL, Front Exhaust Pipe.>
(5) Disconnect the connector (A) from the wastegate control solenoid valve, and remove the air intake
boot from the intake duct No. 1.
2) Drain the engine oil. <Ref. to LU(w/o STI)-11, REPLACEMENT, Engine Oil.>
3) Remove the V-belts. <Ref. to ME(w/o STI)-78, V-BELT, REMOVAL, V-belt.>
4) Remove the generator. <Ref. to SC(w/o STI)-31, REMOVAL, Generator.>
5) Remove the water pump pulley. <Ref. to CO(w/o STI)-16, WATER PUMP, REMOVAL, Water Pump.>
6) Remove the crank pulley. <Ref. to ME(w/o STI)-85, REMOVAL, Crank Pulley.>
7) Remove the engine oil cooler. <Ref. to LU(w/o STI)-35, REMOVAL, Engine Oil Cooler.>
8) Remove the front engine oil cooler pipe assembly. <Ref. to LU(w/o STI)-37, FRONT ENGINE OIL COOL-
ER PIPE, REMOVAL, Engine Oil Cooler Pipe.>
ME-07927
(A)
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ME(w/o STI)-94
Chain Cover
MECHANICAL
9) When working on the engine unit only
NOTE:
When working on the engine unit only, also perform the following steps.
(1) Remove the PCV hose assembly from the chain cover.
NOTE:
To disconnect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the clamp as shown
in the figure, squeeze the ST's handles together and unlock the clamp.
ST 18353AA000 CLAMP PLIERS
10) Remove the clip securing the PCV pipe to the intake manifold.
ME-07928
ST
ME-07351
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ME(w/o STI)-95
Chain Cover
MECHANICAL
11) Remove the PCV pipe from the clip (A), and move the PCV pipe together with the intake duct No. 1 (when
working on the vehicle) to a location that does not interfere operation.
12) Disconnect the vacuum control hose (A) and vacuum hose (B) from the vacuum pipe assembly, and re-
move the vacuum pipe assembly from the chain cover.
ME-08037
(A)
ME-08038
(B)
(A)
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ME(w/o STI)-96
Chain Cover
MECHANICAL
13) Disconnect the connector (A) from the intake oil control solenoid RH, connector (B) from the exhaust oil
control solenoid RH, connector (C) from the intake camshaft position sensor RH, and the connector (D) from
the exhaust camshaft position sensor RH, and then remove the clips (E) and (F) securing the engine har-
ness.
14) Disconnect the connector (A) from the exhaust camshaft position sensor LH and the connector (B) from
the oil level switch, and remove the engine harness stay from the chain cover.
ME-08039
(E)
(C)
(F)
(B)
(D)
(A)
ME-07353
(B)
(A)
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ME(w/o STI)-97
Chain Cover
MECHANICAL
15) Remove the rubber cap from the oil pressure switch.
16) Disconnect the terminal (A) from the oil pressure switch, connector (B) from the engine oil temperature
sensor, connector (C) from the intake oil control solenoid LH, connector (D) from the exhaust oil control so-
lenoid LH, and the connector (E) from the intake camshaft position sensor LH, and then remove the clip (F)
securing the engine harness.
ME-08040
ME-08041
(B)
(A)
(F)
(E)
(C)
(D)
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ME(w/o STI)-98
Chain Cover
MECHANICAL
17) Pull out the oil level gauge (A), and remove the oil level gauge guide (B), crank pulley boss (C), and idler
pulley (D).
18) Remove the bolts securing the chain cover to engine.
ME-07356
(C)
(B)
(A)
(D)
ME-07357
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ME(w/o STI)-99
Chain Cover
MECHANICAL
19) Pry the points shown in the figure with a crowbar wrapped by protective tape, and then remove the chain
cover from the engine.
CAUTION:
The chain cover may contact the protrusion (a) of cam sprocket sensor plate and cause damage.
When removing the chain cover, move the chain cover horizontally until it cannot contact with the
cam sprocket, and then remove it carefully.
ME-08027
(a)
(a)
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ME(w/o STI)-100
Chain Cover
MECHANICAL
20) Remove the O-rings from cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
ME-07432
ME-07943
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ME(w/o STI)-101
Chain Cover
MECHANICAL
21) Remove the liquid gasket from the chain cover and engine unit.
22) Remove the front oil seal from the chain cover.
B: INSTALLATION
1) Apply a light coat of engine oil to the front oil seal inner periphery and outer periphery, and install the front
oil seal to the chain cover using ST.
NOTE:
Use a new front oil seal.
ST 398437700 OIL SEAL INSTALLER
Front oil seal press-fit position:
1
+0
–1
mm (0.0039
+0
–0.0039
in) position from chain cover end face
(A) Chain cover (B) Oil seal (C) Front oil seal press-fit position (1
+0
–1
mm (0.0039
+0
–0.0039
in) posi-
tion from chain cover end face)
ME-06890
ME-06891
(B)
(C)
(A)
ST
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ME(w/o STI)-102
Chain Cover
MECHANICAL
2) Install the O-rings to cylinder head RH, cylinder head LH, cylinder block LH and oil pan upper.
NOTE:
• Use new O-rings.
• Apply a coat of engine oil to the O-rings.
ME-07943
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ME(w/o STI)-103
Chain Cover
MECHANICAL
3) Apply liquid gasket if there are gaps between front camshaft cap and cam carrier (A), cam carrier and cyl-
inder head (B), and cylinder head and cylinder block (C) as shown in the figure.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
ME-07944
(B)
(A)
(A)
(B)
(C)
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ME(w/o STI)-104
Chain Cover
MECHANICAL
4) Apply liquid gasket to the chain cover mating surface and center boss (5 places) as shown in the figure.
NOTE:
• Before applying liquid gasket, degrease the old liquid gasket seal surface of the engine and chain cover.
• Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Liquid gasket applying diameter:
4
±
0.5 mm (0.1575
±
0.0197 in)
(A) 14.5 mm (0.5709 in) (G) 127 mm (5.0000 in) (M) φ4±0.5 mm (0.1575±0.0197 in)
(B) 17.5 mm (0.6890 in) (H) Range B (N) 2 mm (0.0787 in)
(C) Range A (I) Liquid gasket applying position of
mating surfaces of range A
(O) φ12 mm (0.4724 in)
(D) 316.2 mm (12.4488 in) (J) Liquid gasket applying position of
center boss (5 places)
(P) 2.5 mm (0.0984 in)
(E) 24.5 mm (0.9646 in) (K) Liquid gasket applying position of
mating surfaces of range B
(Q) 0.5 mm (0.0197 in)
(F) 18.5 mm (0.7283 in) (L) Liquid gasket applying position of
mating surfaces other than range
A and range B
ME-07383
(C)
A
A
B
A-A
(I)
(M)
(N)
(A)
(B)
(O)
(M)
B-B
(J)
(Q)
(M)
D-D
(L)
C-C
(K)
(M)
(P)
(H)
(E)
(F)
(D)
(G)
C
C
DD
B
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ME(w/o STI)-105
Chain Cover
MECHANICAL
5) Set the chain cover, and tighten the bolts in numerical order as shown in the figure.
CAUTION:
The chain cover may contact the protrusion (a) of cam sprocket sensor plate and cause damage.
When setting the chain cover, move the chain cover horizontally and set it while taking care not to
contact with the cam sprocket.
ME-08027
(a)
(a)
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ME(w/o STI)-106
Chain Cover
MECHANICAL
Tightening torque:
T1: 10 N·m (1.0 kgf-m, 7.4 ft-lb)
T2: 25 N·m (2.5 kgf-m, 18.4 ft-lb)
(A) M6 × 20 (C) M8 × 25 (D) M8 × 60
(B) M6 × 50
ME-07433
(C)
(B)
(5)
(D)
(A)
(A)
(B)
T1
T2
T1
T1
(3)
(1)
(2)
(4)
(C)
(C)
(D)
(D)
T2
T2
T2
T2
(9)
(16)
(17)
(18)
(25)
(15)
(14)
(19)
(20)
(29)
(30)
(21)
(13)
(12)
(11)
(10)
(31)
(28)
(27)
(26)
(6)
(7)
(8)
(22)
(23)
(24)
(32)
T2
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ME(w/o STI)-107
Chain Cover
MECHANICAL
6) Install the idler pulley (D), crank pulley boss (C) and oil level gauge guide (B), and insert the oil level gauge
(A).
NOTE:
• Use a new O-ring to the oil level gauge guide.
• Apply a light coat of engine oil to the O-rings of the oil level gauge guide and the oil level gauge.
Tightening torque:
T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
T2: 36 N·m (3.7 kgf-m, 26.6 ft-lb)
ME-07436
T1
(C)
(B)
(A)
(D)
T2
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ME(w/o STI)-108
Chain Cover
MECHANICAL
7) Connect the terminal (A) to the oil pressure switch, connector (B) to the engine oil temperature sensor,
connector (C) to the intake oil control solenoid LH, connector (D) to the exhaust oil control solenoid LH, and
the connector (E) to the intake camshaft position sensor LH, and fix the engine harness using the clip (F).
NOTE:
The oil pressure switch harness must be positioned toward the left lower side of the vehicle within the range
of 90°.
Tightening torque:
1.5 N·m (0.2 kgf-m, 1.1 ft-lb)
(a) Left side of vehicle
ME-07458
(a)
90
ME-08041
(B)
(A)
(F)
(E)
(C)
(D)
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ME(w/o STI)-109
Chain Cover
MECHANICAL
8) Attach the rubber cap to the oil pressure switch.
9) Connect the connector (A) to the exhaust camshaft position sensor LH and the connector (B) to the oil lev-
el switch, and install the engine harness stay to the chain cover.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
ME-08040
ME-07353
(B)
(A)
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ME(w/o STI)-110
Chain Cover
MECHANICAL
10) Connect the connector (A) to the intake oil control solenoid RH, connector (B) to the exhaust oil control
solenoid RH, connector (C) to the intake camshaft position sensor RH, and the connector (D) to the exhaust
camshaft position sensor RH, and then fix the engine harness using the clips (E) and (F).
11) Install the vacuum pipe assembly to the chain cover, and connect the vacuum control hose (A) and vac-
uum hose (B) to the vacuum pipe assembly.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
ME-08039
(E)
(C)
(F)
(B)
(D)
(A)
ME-08038
(B)
(A)
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ME(w/o STI)-111
Chain Cover
MECHANICAL
12) Install the PCV pipe together with the intake duct No. 1 (when working on the vehicle) to the clip (A).
13) Fix the PCV pipe to the intake manifold using the clip.
ME-08042
(A)
ME-07351
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ME(w/o STI)-112
Chain Cover
MECHANICAL
14) When worked on the engine unit only
NOTE:
When work was done on the engine unit only, also perform the following steps.
(1) Install the PCV hose assembly to the chain cover.
NOTE:
Use a new clamp. To connect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the
clamp as shown in the figure, squeeze the ST's handles together and lock the clamp.
ST 18353AA000 CLAMP PLIERS
15) Install the front engine oil cooler pipe assembly. <Ref. to LU(w/o STI)-41, FRONT ENGINE OIL COOLER
PIPE, INSTALLATION, Engine Oil Cooler Pipe.>
16) Attach the engine oil cooler. <Ref. to LU(w/o STI)-36, INSTALLATION, Engine Oil Cooler.>
17) Install the crank pulley. <Ref. to ME(w/o STI)-87, INSTALLATION, Crank Pulley.>
18) Install the water pump pulley. <Ref. to CO(w/o STI)-17, WATER PUMP, INSTALLATION, Water Pump.>
19) Install the generator. <Ref. to SC(w/o STI)-33, INSTALLATION, Generator.>
20) Install the V-belts. <Ref. to ME(w/o STI)-81, V-BELT, INSTALLATION, V-belt.>
21) Fill engine oil. <Ref. to LU(w/o STI)-11, REPLACEMENT, Engine Oil.>
22) When working on the vehicle
NOTE:
When working on the vehicle, perform the following steps also.
ME-08028
ST
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ME(w/o STI)-113
Chain Cover
MECHANICAL
(1) Install the air intake boot to the intake duct No. 1, then connect the connector (A) to the wastegate con-
trol solenoid valve.
(2) Install the front exhaust pipe. <Ref. to EX(w/o STI)-19, INSTALLATION, Front Exhaust Pipe.>
(3) Install the intake duct No. 2. <Ref. to IN(w/o STI)-32, INTAKE DUCT NO. 2, INSTALLATION, Intake
Duct.>
(4) Install the radiator. <Ref. to CO(w/o STI)-40, INSTALLATION, Radiator.>
C: DISASSEMBLY
1) When removal work was done on the vehicle
NOTE:
When removal work was done on the vehicle, also perform the following steps.
(1) Remove the PCV hose assembly together with the oil catch tank from the chain cover.
NOTE:
To disconnect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the clamp as shown
in the figure, squeeze the ST's handles together and unlock the clamp.
ST 18353AA000 CLAMP PLIERS
ME-07927
(A)
ME-07552
ST
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ME(w/o STI)-114
Chain Cover
MECHANICAL
2) Remove the oil filler cap.
3) Remove the oil pressure switch. <Ref. to LU(w/o STI)-31, REMOVAL, Oil Pressure Switch.>
4) Remove the engine oil temperature sensor. <Ref. to FU(w/o STI)-96, REMOVAL, Engine Oil Temperature
Sensor.>
5) Remove the oil control solenoid. <Ref. to FU(w/o STI)-108, REMOVAL, Oil Control Solenoid.>
6) Remove the camshaft position sensor. <Ref. to FU(w/o STI)-103, REMOVAL, Camshaft Position Sen-
sor.>
D: ASSEMBLY
1) Install the camshaft position sensor. <Ref. to FU(w/o STI)-104, INSTALLATION, Camshaft Position Sen-
sor.>
2) Install the oil control solenoid. <Ref. to FU(w/o STI)-109, INSTALLATION, Oil Control Solenoid.>
3) Install the engine oil temperature sensor. <Ref. to FU(w/o STI)-96, INSTALLATION, Engine Oil Temper-
ature Sensor.>
4) Install the oil pressure switch. <Ref. to LU(w/o STI)-32, INSTALLATION, Oil Pressure Switch.>
5) Install the oil filler cap.
ME-07384
ME-07384
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ME(w/o STI)-115
Chain Cover
MECHANICAL
6) When installation work is done on the vehicle
NOTE:
When installation work is done on the vehicle, also perform the following steps.
(1) Install the PCV hose assembly together with the oil catch tank to the chain cover.
NOTE:
Use a new clamp. To connect the PCV hose assembly, fit the cut outs of the ST with the protrusions on the
clamp as shown in the figure, squeeze the ST's handles together and lock the clamp.
ST 18353AA000 CLAMP PLIERS
E: INSPECTION
Check that the chain cover does not have deformation, cracks and any other damage.
ME-08029
ST
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